Proceedings Volume 9806

Smart Materials and Nondestructive Evaluation for Energy Systems 2016

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Proceedings Volume 9806

Smart Materials and Nondestructive Evaluation for Energy Systems 2016

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Volume Details

Date Published: 8 July 2016
Contents: 12 Sessions, 34 Papers, 9 Presentations
Conference: SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring 2016
Volume Number: 9806

Table of Contents

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Table of Contents

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  • Front Matter: Volume 9806
  • Fuel Cells and Energy Storage
  • SHM
  • Energy Harvesting I
  • Keynote Lecture
  • Wind Energy
  • Materials Processing and Characterization I
  • Propulsion
  • Nuclear Energy
  • Materials Processing and Characterization II
  • Energy Harvesting II
  • Poster Session
Front Matter: Volume 9806
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Front Matter: Volume 9806
This PDF file contains the front matter associated with SPIE Proceedings Volume 9806, including the Title Page, Copyright information, Table of Contents, Introduction, and the Conference Committee listing.
Fuel Cells and Energy Storage
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Nondestructive cell evaluation techniques in SOFC stack manufacturing
Independent from the specifics of the application, a cost efficient manufacturing of solid oxide fuel cells (SOFC), its electrolyte membranes and other stack components, leading to reliable long-life stacks is the key for the commercial viability of this fuel cell technology.

Tensile and shear stresses are most critical for ceramic components and especially for thin electrolyte membranes as used in SOFC cells. Although stack developers try to reduce tensile stresses acting on the electrolyte by either matching CTE of interconnects and electrolytes or by putting SOFC cells under some pressure – at least during transient operation of SOFC stacks ceramic cells will experience some tensile stresses. Electrolytes are required to have a high Weibull characteristic fracture strength. Practical experiences in stack manufacturing have shown that statistical fracture strength data generated by tests of electrolyte samples give limited information on electrolyte or cell quality. In addition, the cutting process of SOFC electrolytes has a major influence on crack initiation.

Typically, any single crack in one the 30 to 80 cells in series connection will lead to a premature stack failure drastically reducing stack service life. Thus, for statistical reasons only 100% defect free SOFC cells must be assembled in stacks. This underlines the need for an automated inspection. So far, only manual processes of visual or mechanical electrolyte inspection are established. Fraunhofer IKTS has qualified the method of optical coherence tomography for an automated high throughput inspection. Alternatives like laser speckle photometry and acoustical methods are still under investigation.
Investigating effectiveness of activated carbons of natural sources on various supercapacitors
Activated carbon can be produced from natural sources, such as pistachio and acorn shells, which can be an inexpensive and sustainable sources of natural wastes for the energy storage devices, such as supercapacitors. The carbonaceous materials used in this study were carbonized at the temperatures of 700°C and 900°C after the stabilization process at 240°C for two hours. These shells showed approximately 60% carbon yield. Carbonized nutshells were chemically activated using1wt% potassium hydroxide (KOH). Activated carbon powders with polyvinylidene fluoride (PVdF) were used to construct carbon electrodes. A 1M of tetraethylammonium tetrafluoroborate (TEABF4) and propylene carbonate (PC) were used as electrolytes. Electrochemical techniques, such as cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) were used for the characterization of the supercapacitors. Scanning electron microscopy (SEM) was used to inspect the surface texture of the activated carbons. Activated pistachio shells carbonized at 700°C showed more porous surface texture than those carbonized at 900°C. Effects of the carbonization temperatures were studied for their electrochemical characteristics. The shells carbonized at 700°C showed better electrochemical characteristics compared to those carbonized at 900°C. The test results provided about 27,083 μF/g specific capacitance at a scan rate of 10mV/s. This study showed promising results for using these activated carbons produced from the natural wastes for supercapacitor applications.
SHM
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Effects of temperature variations on guided waves propagating in composite structures
Siavash Shoja, Viktor Berbyuk, Anders Boström
Effects of temperature on guided waves propagating in composite materials is a well-known problem which has been investigated in many studies. The majority of the studies is focused on effects of high temperature. Understanding the effects of low temperature has major importance in composite structures and components which are operating in cold climate conditions such as e.g. wind turbines operating in cold climate regions. In this study first the effects of temperature variations on guided waves propagating in a composite plate is investigated experimentally in a cold climate chamber. The material is a common material used to manufacture rotor blades of wind turbines. The temperature range is 25°C to −25°C and effects of temperature variations on amplitude and phase shift of the received signal are investigated. In order to apply the effects of lowering the temperature on the received signal, the Baseline Signal Stretch (BSS) method is modified and used. The modification is based on decomposing the signal into symmetric and asymmetric modes and applying two different stretch factors on each of them. Finally the results obtained based on the new method is compared with the results of application of BSS with one stretch factor and experimental measurements. Comparisons show that an improvement is obtained using the BSS with the mode decomposition method at temperature variations of more than 25°C.
Smart patch integration development of compression connector structural health monitoring in overhead transmission lines
Hong Wang, Jy-An John Wang, Fei Ren, et al.
Integration of smart patches into full-tension splice connectors in overhead power transmission lines was investigated. Lead zirconate titanate (PZT) -5A was used as a smart material and an aluminum beam was used as a host structure. Negative electrode termination was examined by using copper adhesive tape and direct bonding methods. Various commercial adhesives were studied for PZT integration onto the host structure. Aluminum beam specimens with integrated PZT smart patches were tested under thermal cycling at a temperature of 125°C, which is the higher-end temperature experienced by in-service aluminum conductor steel-reinforced cables. Electromechanical impedance (EMI) measurements were conducted at room temperature, and the root mean square deviation (RMSD) of the conductance signals was used to analyze the EMI data.

It has been shown that the negative electrode method has an important effect on the performance of the integrated PZT. The PZT displayed more susceptibility to cracking when copper tape was used than when direct bonding was used. The reliability of PZT in direct bonding depended on the adhesives used in bonding layers. Although a hard alumina–based adhesive can lead to cracking of the PZT, a high-temperature epoxy with adequate flexibility, such as Duralco 4538D, can provide the desired performance under target thermal cycling conditions. The RMSD parameter can characterize conductance signatures effectively. It also was demonstrated that RMSD can be used to quantify the fatigue of the PZT integration system, although RMSD is used primarily as a damage index in monitoring structural health.
Optimization of monitoring and inspections in the life-cycle of wind turbines
Anu Hanish Nithin, Piotr Omenzetter
The past decade has witnessed a surge in the offshore wind farm developments across the world. Although this form of cleaner and greener energy is beneficial and eco-friendly, the production of wind energy entails high life-cycle costs. The costs associated with inspections, monitoring and repairs of wind turbines are primary contributors to the high costs of electricity produced in this way and are disadvantageous in today’s competitive economic environment. There is limited research being done in the probabilistic optimization of life-cycle costs of offshore wind turbines structures and their components. This paper proposes a framework for assessing the life cycle cost of wind turbine structures subject to damage and deterioration. The objective of the paper is to develop a mathematical probabilistic cost assessment framework which considers deterioration, inspection, monitoring, repair and maintenance models and their uncertainties. The uncertainties are etched in the accuracy and precision of the monitoring and inspection methods and can be considered through the probability of damage detection of each method. Schedules for inspection, monitoring and repair actions are demonstrated using a decision tree. Examples of a generalised deterioration process integrated with the cost analysis using a decision tree are shown for a wind turbine foundation structure.
Disturbance observer based pitch control of wind turbines for disturbance rejection
Yuan Yuan, Xu Chen, Jiong Tang
In this research, a disturbance observer based (DOB) control scheme is illustrated to reject the unknown low frequency disturbances to wind turbines. Specifically, we aim at maintaining the constant output power but achieving better generator speed regulation when the wind turbine is operated at time-varying and turbulent wind field. The disturbance observer combined with a filter is designed to asymptotically reject the persistent unknown time-varying disturbances. The proposed algorithm is tested in both linearized and nonlinear NREL offshore 5-MW baseline wind turbine. The application of this DOB pitch controller achieves improved power and speed regulation in Region 3 compared with a baseline gain scheduling PID collective controller both in linearized and nonlinear plant.
Energy Harvesting I
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Energy harvesting from dancing: for broadening in participation in STEM fields
Energy harvesting from structure vibration, human motion or environmental source has been the focus of researchers in the past few decades. This paper proposes a novel design that is suitable to harvest energy from human motions such as dancing or physical exercise and use the device to engage young students in Science, Technology, Engineering and Math (STEM) fields and outreach activities. The energy harvester (EH) device was designed for a dominant human operational frequency range of 1–5 Hz and it can be wearable by human. We proposed to incorporate different genres of music coupled with energy harvesting technologies for motivation and energy generation. Students will learn both science and art together, since the energy harvesting requires understanding basic physical phenomena and the art enables various physical movements that imparts the largest motion transfer to the EH device. Therefore, the systems are coupled to each other. Young people follow music updates more than robotics or energy harvesting researches. Most popular videos on YouTube and VEVO are viewed more than 100 million times. Perhaps, integrating the energy harvesting research with music or physical exercise might enhance students’ engagement in science, and needs investigation. A multimodal energy harvester consisting of piezoelectric and electromagnetic subsystems, which can be wearable in the leg, is proposed in this study. Three piezoelectric cantilever beams having permanent magnets at the ends are connected to a base through a slip ring. Stationary electromagnetic coils are installed in the base and connected in series. Whenever the device is driven by any oscillation parallel to the base, the unbalanced rotor will rotate generating energy across the stationary coils in the base. In another case, if the device is driven by an oscillation perpendicular to the base, a stress will be induced within the cantilever beams generating energy across the piezoelectric materials.
Magnetoelastic beam with extended polymer for low frequency vibration energy harvesting
Alwathiqbellah Ibrahim, Shahrzad Towfighian, Mohammad Younis, et al.
Ambient energy in the form of mechanical kinetic energy is mostly considered waste energy. The process of scavenging and storing such energy is known as energy harvesting. Energy harvesting from mechanical vibration is performed using resonant energy harvesters (EH) with two major goals: enhancing the power scavenged at low frequency sources of vibrations, and increasing the efficiency of scavenging energy by increasing the bandwidth near the resonant frequency. Toward such goals, we propose a piezoelectric EH of a composite cantilever beam with a tip magnet facing another magnet at a distance. The composite cantilever consists of a piezoelectric bimorph with an extended polymer material. With the effect of the nonlinearity of the magnetic force, higher amplitude can be achieved because of the generated bi-stability oscillations of the cantilever beam under harmonic excitation. The contribution of the this paper is to demonstrate lowering the achieved resonant frequency down to 17 Hz compared to 100 Hz for the piezoelectric bimorph beam without the extended polymer. Depending on the magnetic distance, the beam responses are divided to mono and bi-stable regions, for which we investigate static and dynamic behaviors. The dynamics of the system and the frequency and voltage responses of the beam are obtained using the shooting method.
Multiple piezo-patch energy harvesters integrated to a thin plate with AC-DC conversion: analytical modeling and numerical validation
Plate-like components are widely used in numerous automotive, marine, and aerospace applications where they can be employed as host structures for vibration based energy harvesting. Piezoelectric patch harvesters can be easily attached to these structures to convert the vibrational energy to the electrical energy. Power output investigations of these harvesters require accurate models for energy harvesting performance evaluation and optimization. Equivalent circuit modeling of the cantilever-based vibration energy harvesters for estimation of electrical response has been proposed in recent years. However, equivalent circuit formulation and analytical modeling of multiple piezo-patch energy harvesters integrated to thin plates including nonlinear circuits has not been studied. In this study, equivalent circuit model of multiple parallel piezoelectric patch harvesters together with a resistive load is built in electronic circuit simulation software SPICE and voltage frequency response functions (FRFs) are validated using the analytical distributedparameter model. Analytical formulation of the piezoelectric patches in parallel configuration for the DC voltage output is derived while the patches are connected to a standard AC-DC circuit. The analytic model is based on the equivalent load impedance approach for piezoelectric capacitance and AC-DC circuit elements. The analytic results are validated numerically via SPICE simulations. Finally, DC power outputs of the harvesters are computed and compared with the peak power amplitudes in the AC output case.
U-shape magnetostrictive vibration based power generator for universal use
Vibrational power generator extracts electrical energy from ambient vibration. Author invented novel configuration using magnetostrictive material. The device is based on parallel beams of iron-gallium alloy and magnetic material, and features high efficiency, high robustness, and low electrical impedance. In this paper, author proposes U-shape generator for universal use. It consists of the parallel beams and fixed and free end beams forming U-shape frame flexibly modified for variety of mechanical input. Miniature U-shape prototype using Fe-Ga rod 6 by 0.5 by 13 mm3 exhibited average power of 3.7 mW under vibration of 166 Hz and 2.5 G. L-shape type was demonstrated to generate electromotive force by two directional vibrations. In switch type, maximum energy of 0.7 mJ was retrieved by one pushing force. The performances are sufficient to drive wireless module for heath monitoring and remote control.
Keynote Lecture
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Highlights and challenges in nondestructive evaluation for metallic and composite structures
The paper presents methods and techniques oriented towards structural health monitoring (SHM) and (ENDT) for both metallic and composite structures. Particularly the paper is dedicated to elastic waves propagation phenomenon, scanning laser vibrometry, electromechanical impedance and terahertz spectroscopy. Selected numerical modelling aspects of the phenomena related to the mentioned methods are addressed. Moreover it covers the main disciplines which are related to above mentioned techniques as piezoelectric sensors and transducers, and signal processing. The signal processing approach is crucial allowing extracting damage related features from the gathered signals.

Investigated damage is in the form of mechanical failures as cracks, delaminations, debonding, voids. Also methods dedicated to thermal degradation, moisture and chemical contamination are shown. Presented methods are also suitable for performance of bonded joints assessment. Problem of external factor (temperature, load) on investigated methods is also discussed in this paper. The characteristic of each method is summarized by a critical look. Promising combination of selected techniques should lead to an innovative approach to ensure safety operation of structures. All problems have been dealt with a hybrid experimental – numerical approach.
Wind Energy
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Development of novel general equation for multistage epicyclic gearset with corrected teeth: non-constrained approach
Piotr Kijanka, Adam Jablonski, Kajetan Dziedziech, et al.
A large number of commercial systems for condition monitoring of most common planetary gearboxes used in wind turbines and mining machinery have been developed for years. However nowadays, multistage constructions are encountered in industries. These are not necessarily planetary, but generally epicyclic. Current state of the art, according to the authors knowledge, does not give general equations for a case where multistage systems are considered, where some of the gears consist all moving parts. Hence, currently available CMS systems are not suitable for condition monitoring of these kinds of systems.

The paper presents a new general equation, which allows calculating the characteristic frequencies of any kind of multistage gear sets, as a result of theoretical investigation. Illustrated solution does not assume a fixed speed of any element. Moreover, presented equation takes into account corrected teeth, making developed equations most general from all available in tribology science. Presented scientific development is currently implemented in a modern European CMS.
Quantifying voids effecting delamination in carbon/epoxy composites: static and fatigue fracture behavior
I. Hakim, D. May, M. Abo Ras, et al.
On the present work, samples of carbon fiber/epoxy composites with different void levels were fabricated using hand layup vacuum bagging process by varying the pressure. Thermal nondestructive methods: thermal conductivity measurement, pulse thermography, pulse phase thermography and lock-in-thermography, and mechanical testing: modes I and II interlaminar fracture toughness were conducted. Comparing the parameters resulted from the thermal nondestructive testing revealed that voids lead to reductions in thermal properties in all directions of composites. The results of mode I and mode II interlaminar fracture toughness showed that voids lead to reductions in interlaminar fracture toughness. The parameters resulted from thermal nondestructive testing were correlated to the results of mode I and mode II interlaminar fracture toughness and voids were quantified.
Terahertz ISAR and x-ray imaging of wind turbine blade structures
Robert Martin, Christopher S. Baird, Robert H. Giles, et al.
During the manufacture of wind turbine blades, internal defects can form which negatively affect their structural integrity and may lead to premature failure. The purpose of this research was to conduct preliminary testing of nondestructive evaluation techniques that have the potential to scale up to larger areas. The techniques investigated were: Terahertz frequency fully-polarimetric inverse synthetic aperture radar (ISAR), and x-ray imaging. The terahertz ISAR technique employed standard polarimetric radar cross-section processing, and additionally applied an optimized polarimetry transformation known as the Euler transformation. Also, image back-rotation and compositing algorithms were used to combine multiple ISAR images into a single image to aid in defect detection. ISAR data were collected using a frequency modulated continuous wave 100 GHz radar system. The x-ray technique utilized a commercial airport cargo x-ray scanner. Multiple fiberglass samples with defects representative of manufacturing wind turbine blade defects were investigated using each of the techniques. Out-of-plane defects and resin dry patches were the primary defects of interest in these samples. Images were created of each sample using each of the techniques. Comparing these images with defect diagrams of the samples indicated that these techniques could effectively indicate the presence of certain defects.
Neuro-fuzzy computing for vibration-based damage localization and severity estimation in an experimental wind turbine blade with superimposed operational effects
Simon Hoell, Piotr Omenzetter
Fueled by increasing demand for carbon neutral energy, erections of ever larger wind turbines (WTs), with WT blades (WTBs) with higher flexibilities and lower buckling capacities lead to increasing operation and maintenance costs. This can be counteracted with efficient structural health monitoring (SHM), which allows scheduling maintenance actions according to the structural state and preventing dramatic failures. The present study proposes a novel multi-step approach for vibration-based structural damage localization and severity estimation for application in operating WTs. First, partial autocorrelation coefficients (PACCs) are estimated from vibrational responses. Second, principal component analysis is applied to PACCs from the healthy structure in order to calculate scores. Then, the scores are ranked with respect to their ability to differentiate different damage scenarios. This ranking information is used for constructing hierarchical adaptive neuro-fuzzy inference systems (HANFISs), where cross-validation is used to identify optimal numbers of hierarchy levels. Different HANFISs are created for the purposes of structural damage localization and severity estimation. For demonstrating the applicability of the approach, experimental data are superimposed with signals from numerical simulations to account for characteristics of operational noise. For the physical experiments, a small scale WTB is excited with a domestic fan and damage scenarios are introduced non-destructively by attaching small masses. Numerical simulations are also performed for a representative fully functional small WT operating in turbulent wind. The obtained results are promising for future applications of vibration-based SHM to facilitate improved safety and reliability of WTs at lower costs.
Materials Processing and Characterization I
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Artificial feel system using magneto-rheological fluid on aircraft control stick
The conventional feel system in aircraft occupies large space in the cockpit and has complicated designs. The primary objective of this research is to develop an artificial feel force system that can overcome some drawbacks of the current system. A novel feel system using magneto-rheological (MR) fluid is constructed to precisely control the shear stress under the magnetic field. To validate the functionality of the MR artificial feel system, the final system is fabricated and multiple tests are performed to acquire force-velocity characteristics that are compared to the mathematical model derived. In addition, the PID closed loop control algorithm is developed to simulate the dynamic system model. Both experimental and simulation results are compared to validate the derived system model. The system response time and sampling rates are evaluated and compared to the conventional system at the end. It is concluded that the developed artificial feel system can precisely control and acts as a fail proof system when incorporated with a modern fly-by-wire aircraft system.
A novel methodology for self-healing at the nanoscale in CNT/epoxy composites
E. Quigley, S. Datta, A. Chattopadhyay
Self-healing materials have the potential to repair induced damage and extend the service life of aerospace or civil components as well as prevent catastrophic failure. A novel technique to provide self-healing capabilities at the nanoscale in carbon nanotube/epoxy nanocomposites is presented in this paper. Carbon nanotubes (CNTs) functionalized with the healing agent (dicyclopentadiene) were used to fabricate self-healing CNT/epoxy nanocomposite films. The structure of CNTs was considered suitable for this application since they are nanosized, hollow, and provide a more consistent size distribution than polymeric nanocapsules. Specimens with different weight fractions of the functionalized CNTs were fabricated to explore the effect of weight fraction of functionalized CNTs on the extent of healing. Optical micrographs with different fluorescent filters showed partial or complete healing of damage approximately two to three weeks after damage was induced. Results indicate that by using CNTs to encapsulate a healing agent, crack growth in self-healing CNT/epoxy nanocomposites can be retarded, leading to safer materials that can autonomously repair itself.
Ensuring near-optimum homogeneity and densification levels in nano-reinforced ceramics
Konstantinos G. Dassios, Nektaria-Marianthi Barkoula, Panagiota Alafogianni, et al.
The development of a new generation of high temperature ceramic materials for aerospace applications, reinforced at a scale closer to the molecular level and three orders of magnitude less than conventional fibrous reinforcements, by embedded carbon nanotubes, has recently emerged as a uniquely challenging scientific effort. The properties of such materials depend strongly on two main factors: i) the homogeneity of the dispersion of the hydrophobic medium throughout the ceramic volume and ii) the ultimate density of the resultant product after sintering of the green body at the high-temperatures and pressures required for ceramic consolidation. The present works reports the establishment of two independent experimental strategies which ensure achievement of near perfect levels of tube dispersion homogeneity and fully dense final products. The proposed methodologies are validated across non-destructive evaluation data of materials performance.
Propulsion
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Performance of PZT stacks under high-field electric cycling at various temperatures in heavy-duty diesel engine fuel injectors
Hong Wang, Sung-Min Lee, Hua-Tay Lin, et al.
Testing and characterization of large prototype lead zirconate titanate (PZT) stacks present substantial technical challenges to electronic systems. The work in this study shows that an alternative approach can be pursued by using subunits extracted from prototype stacks. Piezoelectric and dielectric integrity was maintained even though the PZT plate specimens experienced an additional loading process involved with the extraction after factory poling. Extracted 10-layer plate specimens were studied by an electric cycle test under an electric field of 3.0/0.0 kV/mm, 100 Hz to 108 cycles, both at room temperature (22°C) and at 50°C. The elevated temperature had a defined impact on the fatigue of PZT stacks. About 48 and 28% reductions were observed in the piezoelectric and dielectric coefficients, respectively, after 108 cycles at 50°C, compared with reductions of 25 and 15% in the respective coefficients at 22°C. At the same time, the loss tangent varied to a limited extent. The evolution of PZT–electrode interfacial layers or nearby dielectric layers should account for the difference in the fatigue rates of piezoelectric and dielectric coefficients. But the basic contribution to observed fatigue may result from the buildup of a bias field that finally suppressed the motion of the domain walls. Finally, monitoring of dielectric coefficients can be an effective tool for on-line lifetime prediction of PZT stacks in service if a failure criterion is defined properly.
Nuclear Energy
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Develop an piezoelectric sensing based on SHM system for nuclear dry storage system
In US, there are over 1482 dry cask storage system (DCSS) in use storing 57,807 fuel assemblies. Monitoring is necessary to determine and predict the degradation state of the systems and structures. Therefore, nondestructive monitoring is in urgent need and must be integrated into the fuel cycle to quantify the “state of health” for the safe operation of nuclear power plants (NPP) and radioactive waste storage systems (RWSS). Innovative approaches are desired to evaluate the degradation and damage of used fuel containers under extended storage. Structural health monitoring (SHM) is an emerging technology that uses in-situ sensory system to perform rapid nondestructive detection of structural damage as well as long-term integrity monitoring. It has been extensively studied in aerospace engineering over the past two decades. This paper presents the development of a SHM and damage detection methodology based on piezoelectric sensors technologies for steel canisters in nuclear dry cask storage system. Durability and survivability of piezoelectric sensors under temperature influence are first investigated in this work by evaluating sensor capacitance and electromechanical admittance. Toward damage detection, the PES are configured in pitch catch setup to transmit and receive guided waves in plate-like structures. When the inspected structure has damage such as a surface defect, the incident guided waves will be reflected or scattered resulting in changes in the wave measurements. Sparse array algorithm is developed and implemented using multiple sensors to image the structure. The sparse array algorithm is also evaluated at elevated temperature.
Materials Processing and Characterization II
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NDE applications in microelectronic industries
N. Meyendorf, M. Oppermann, P. Krueger, et al.
New concepts in assembly technology boost our daily life in an unknown way. High end semiconductor industry today deals with functional structures down to a few nanometers. ITRS roadmap predicts an ongoing decrease of the “DRAM half pitch” over the next decade. Packaging of course is not intended to realize pitches at the nanometer scale, but has to face the challenges of integrating such semiconductor devices with smallest pitch and high pin counts into systems. Advanced techniques of nondestructive evaluation (NDE) with resolutions in volume better than 1 micrometer vixen size are urgently needed for the safety and reliability of electronic systems, especially those that are used in long living applications. The development speed of integrated circuits is still very high and is not expected to decrease in the next future. The integration density of microelectronic devices is increasing, the dimensions become smaller and the number of I/O's is getting higher. The development of new types of packages must be done with respect to reliability issues. Potential damage sources must be identified and finally avoided in the new packages. In power electronics production the condition monitoring receives a lot of interest to avoid electrical shortcuts, dead solder joints and interface cracking. It is also desired to detect and characterize very small defects like transportation phenomenon or Kirkendall voids. For this purpose, imaging technologies with resolutions in the sub-micron range are required.
Energy Harvesting II
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Wide operation frequency band magnetostrictive vibration power generator using nonlinear spring constant by permanent magnet
We study magnetostrictive vibration based power generator using iron-gallium alloy (Galfenol). The generator is advantages over conventional, such as piezoelectric material in the point of high efficiency highly robust and low electrical impedance. Generally, the generator exhibits maximum power when its resonant frequency matches the frequency of ambient vibration. In other words, the mismatch of these frequencies results in significant decrease of the output. One solution is making the spring characteristics nonlinear using magnetic force, which distorts the resonant peak toward higher or lower frequency side. In this paper, vibrational generator consisting of Galfenol plate of 6 by 0.5 by 13 mm wound with coil and U shape-frame accompanied with plates and pair of permanent magnets was investigated. The experimental results show that lean of resonant peak appears attributed on the non-linear spring characteristics, and half bandwidth with magnets is 1.2 times larger than that without. It was also demonstrated that the addition of proof mass is effective to increase the sensitivity but also the bandwidth. The generator with generating power of sub mW order is useful for power source of wireless heath monitoring for bridge and factory machine.
Fatigue study and improve reliability of cantilever type micro piezoelectric energy harvesters reinforced with flexible adhesive conductive tape
T. K. Lin, Y. C. Hsieh, C. T. Chen, et al.
Cantilever type piezoelectric energy harvester (PEH) is widely adopted in the design of vibration energy harvesters because of simple, effective and easy to fabricate. When the PEH is working under excitation of continuous vibration sources, like mounting on motors, reliability and durability is a major concern. The failure mode and fatigue issues will be important design considerations in field applications. Since the largest strain of a cantilever structure is located in the clamping position of fixed end, the location is therefore the weakest point of the structure and the hot zone of mechanical cracks. The failure mode due to fatigue under long time excitation of vibration sources is typically continuously developing small cracks on the piezoelectric PZT films till tearing the surface electrodes and caused open circuit to the output circuitry. Therefore, extending the lifetime with minimize the surface electrodes cracking becomes a key point for field applications.

Previously, we focused on the output performance of PEH. At PowerMEMS 2014 [1], we presented a high performance PEH based on PZT thin films fabricated with a homemade PZT deposition equipment on stainless steel substrates. We confirmed that the stainless steel based PEH can generate better output power than silicon based devices under the same vibration excitation levels, and also the stainless based PEH can have longer lifetime when excited at higher vibration levels due to better mechanical strength. In this study, we tried to further reinforce the PEH with a conductive adhesive tape sticking on the surface electrode near the clamping position. We investigated the change of failure mode and mechanical behaviors, including the frequency bandwidth and non-linearity of the piezoelectric energy harvester.

The PEH devices was mounted on a shaker for long time testing with vibration frequency set around 120Hz at 0.5g, 0.6g, and 0.7g acceleration vibration levels. The electrodes of the PEH device were cracked after 13 million cycles under 0.5g and 1 million cycles under 0.6g. The PEH has significant output power decreasing after the electrode is cracked and before being fully open circuit. The cracks of stainless steel substrate was also found after 1 million cycles under 0.7g vibration. For the device reinforced with conductive adhesive tape, we can see a steady output without degradation extended to more than 1.5 million cycles under 0.7g vibration. The other interesting finding in this study is with the added damping after adhering the conductive tape, the frequency bandwidth increased from 1.5Hz to 4Hz under 0.5g vibration level while the resonance frequency increased from 105Hz to 128Hz. Moreover, the reinforced devices have much better stability and linearity performance compared with the original devices. All the experimental details and discussion of the flexible conductive adhesive tape reinforced PEH will all be detailed in this paper.
Parameter study and optimization for piezoelectric energy harvester for TPMS considering speed variation
In this paper, we perform design parameter study and design optimization for a piezoelectric energy harvester considering vehicle speed variation. Initially, a FEM model using ANSYS is developed to appraise the performance of a piezoelectric harvester in a rotating tire. The energy harvester proposed here uses the vertical deformation at contact patch area from the car weight and centrifugal acceleration. This harvester is composed of a beam which is clamped at both ends and a piezoelectric material is attached on the top of that. The piezoelectric material possesses the 31 mode of transduction in which the direction of applied field is perpendicular to that of the electric field. To optimize the harvester performance, we would change the geometrical parameters of the harvester to obtain the maximum power. One of the main challenges in the design process is obtaining the required power while considering the constraints for harvester weight and volume. These two concerns are addressed in this paper. Since the final goal of this study is the development of an energy harvester with a wireless sensor system installed in a real car, the real time data for varied velocity of a vehicle are taken into account for power measurements. This study concludes that the proposed design is applicable to wireless tire sensor systems.
Design and experimental evaluation of flextensional-cantilever based piezoelectric transducers for flow energy harvesting
Hyeong Jae Lee, Stewart Sherrit, Luis Phillipe Tosi, et al.
Cantilever type piezoelectric harvesters, such as bimorphs, are typically used for vibration induced energy harvesting. However, a major drawback of a piezoelectric bimorph is its brittle nature in harsh environments, precipitating short life-times as well as output power degradation. The emphasis in this work is to design robust, highly efficient piezoelectric harvesters that are capable of generating electrical power in the milliwatt range. Various harvesters were modeled, designed and prototyped, and the flextensional actuator based harvester, where the metal cantilever is mounted and coupled between two flextensional actuators, was found to be a viable alternative to the cantilever type piezoelectric harvesters. Preliminary tests show that these devices equipped with 5x5x36 mm two piezoelectric PZT stacks can produce greater than 50 mW of power under air flow induced vibrations.
Comparative studies on different nanofiber photocatalysts for water splitting
Abdulaziz Alharbi, Ibrahim M. Alarifi, Waseem S. Khan, et al.
Water splitting using photocatalyst has become a topic of recent investigation since it has the potential of producing hydrogen for clean energy from sunlight. An extensive number of solid photocatalysts have been studied for overall water splitting in recent years. In this study, two methods were employed to synthesize two different photocatalysts for water splitting. The first method describes the synthesis of nickel oxide-loaded strontium titanate (NiO-SrTiO3) particles on electrospun polyacrylonitrile (PAN) nanofibers incorporated with graphene nanoplatelets for water splitting. The electrospun PAN fibers were first oxidized at 270°C for two hours and subsequently immersed in a solution containing ethanol, titanium (IV)-isopropoxide [C12H28O4Ti] and strontium nitrate [Sr(NO3)2]. This solution was then treated with NiO nanoparticles dispersed in toluene. The surface treated PAN fibers were annealed at 600°C in air for 1 hour to transform fibers into a crystalline form for improved photocatalyst performance. In the second method, coaxial electrospinning process was used to produce core/shell strontium titanate/nickel oxide (SrTiO3-NiO) nanofibers. In coaxial method, poly (vinyl pyrrolidone) (PVP) was dissolved in deionized (DI) water, and then titanium (IV) isopropoxide [C12H28O4Ti] and strontium nitrate [Sr(NO3)2] were added into the solution to form the inner (core) layer. For outer (shell) solution, polyacrylonitrile (PAN) polymer was dissolved in dimethylformamide (DMF) at a weight ratio of 10:90 and then nickel oxide was mixed with the solution. Ultraviolet (UV) spectrophotometry and static contact angle measurement techniques were employed to characterize the structural properties of photocatalysts produced by both methods and a comparison was made between the two photocatalysts. The morphology and diameter of the nanofibers were observed by scanning electron microscopy (SEM). The structure and crystallinity of the calcined nanofibers were also observed by means of X-ray diffraction (XRD).
Poster Session
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Energy harvesting under excitation of clamped-clamped beam
In this article, a piezoelectric energy harvesting has been developed experimentally and theoretically based on Euler- Bernoulli Theory. A PVDF piezoelectric thick film has attached along of clamped-clamped beam under sinusoidal base excitation of shaker. The results showed a good agreement between the experimental and simulation of suggested model. The voltage output frequency response function (FRF), current FRF, and output power has been studied under short and open circuit conditions at first vibration mode. The mode shape of the clamped-clamped beam for first three resonance frequency has been modeled and investigated using COMSOL Multiphysics and MATLAB.
A study on the multilayer π-type thermoelectric power generation module using the metal direct bonding technology
Hiroshi Sato, So Baba, Teturo Yanaseko, et al.
The thermoelectric power generation device can take out electric energy from thermal energy directly. In order to transform a difference of temperature into electric power efficiently, it is common to make the thermoelement of N-type and P-type into pi structure. Since the thermoelectric power of an element was small, much pi structures needed to be connected with series, but when a large number were connected with series, there was a problem that internal resistance will become large.

In this study, we propose a new multilayer π-type structure sandwiched between an insulating layer using a metal direct bonding technology. By using this technique, significantly lowered layered structure the electrical resistance of the joint portion, because it can be produced by laminating at least one hundred sheets at a time, even when using a metal material having low Seebeck effect, a sufficiently practical level. It can boost the voltage, a possible cost reduction of the device itself. Further, since the laminated π type structure fabricated. Each interface is tightly bonded by eutectic reaction, it is possible to use a structure having a power generation function.
Acoustic metamaterial bar with non-linear spring-mass cells
Guochang Lin, Ge He, Hongwei Sun
In this paper we present experimental and theoretical results on an acoustic metamaterial bar that exhibits negative effective mass and negative effective stiffness. A one-dimensional acoustic metamaterial bar with an group of non-linear spring-mass cells in was fabricated. The frequency characteristics of the acoustic metamaterial have the same form as that of the permittivity in metals due to the plasma oscillation. We also provide a theory to explain the simulation results. And numerical simulations reveal that the actual working mechanism of the proposed metamaterial bar is based on the concept of conventional mechanical vibration absorbers. It uses the incoming elastic wave in the bar to resonate the integrated spring-mass-damper absorbers to vibrate in their optical mode at frequencies close to but above their local resonance frequencies to create shear forces and bending moments to straighten the bar and stop the wave propagation. Moreover, we design a finite periodic system composed of such basic units to confirm that the modeling and analysis techniques are available.
The effect of corrosion on the fatigue life of aluminum alloys
The corrosion behavior of metallic structures is an important factor of material performance. In case of aluminum matrix composites corrosion occurs via electrochemical reactions at the interface between the metallic matrix and the reinforcement. The corrosion rate is determined by equilibrium between two opposing electrochemical reactions, the anodic and the cathodic. When these two reactions are in equilibrium, the flow of electrons from each reaction type is balanced, and no net electron flow occurs. In the present study, aluminum alloy tensile-shape samples are immersed in NaCl solution with an objective to study the effect of the controlled pitting corrosion in a specific area. The rest of the material is completely sealed. In order to investigate the effect of pitting corrosion on the material performance, the specimens were subjected to cyclic loading. The effect of corrosion on the fatigue life was assessed using two complimentary nondestructive methods, infrared thermography and acoustic emission.
Acoustic emission of fire damaged fiber reinforced concrete
The mechanical behavior of a fiber-reinforced concrete after extensive thermal damage is studied in this paper. Undulated steel fibers have been used for reinforcement. After being exposed to direct fire action at the temperature of 850°C, specimens were subjected to bending and compression in order to determine the loss of strength and stiffness in comparison to intact specimens and between the two types. The fire damage was assessed using nondestructive evaluation techniques, specifically ultrasonic pulse velocity (UPV) and acoustic emission (AE). Apart from the strong, well known, correlation of UPV to strength (both bending and compressive), AE parameters based mainly on the frequency and duration of the emitted signals after cracking events showed a similar or, in certain cases, better correlation with the mechanical parameters and temperature. This demonstrates the sensitivity of AE to the fracture incidents which eventually lead to failure of the material and it is encouraging for potential in-situ use of the technique, where it could provide indices with additional characterization capability concerning the mechanical performance of concrete after it subjected to fire.
Design of piezoelectric transformer for DC/DC converter with stochastic optimization method
Dejan Vasic, Lionel Vido
Piezoelectric transformers were adopted in recent year due to their many inherent advantages such as safety, no EMI problem, low housing profile, and high power density, etc. The characteristics of the piezoelectric transformers are well known when the load impedance is a pure resistor. However, when piezoelectric transformers are used in AC/DC or DC/DC converters, there are non-linear electronic circuits connected before and after the transformer. Consequently, the output load is variable and due to the output capacitance of the transformer the optimal working point change. This paper starts from modeling a piezoelectric transformer connected to a full wave rectifier in order to discuss the design constraints and configuration of the transformer. The optimization method adopted here use the MOPSO algorithm (Multiple Objective Particle Swarm Optimization). We start with the formulation of the objective function and constraints; then the results give different sizes of the transformer and the characteristics. In other word, this method is looking for a best size of the transformer for optimal efficiency condition that is suitable for variable load. Furthermore, the size and the efficiency are found to be a trade-off. This paper proposes the completed design procedure to find the minimum size of PT in need. The completed design procedure is discussed by a given specification. The PT derived from the proposed design procedure can guarantee both good efficiency and enough range for load variation.
Development of an advanced, high-frequency GPR technique for the assessment of concrete structures: from modeling predictions to experimental results
Eleni Cheilakou, Theodore E. Matikas
The main objective of this paper is to develop a portable, advanced and high operating frequency GPR prototype system, which will be able to provide an increased sensitivity and resolution in terms of defects detectability at a penetration depth range up to 40-50 cm in concrete. For this purpose, the theoretical assessment of multiple GPR antenna-frequency approaches was initially performed using electromagnetic wave simulation tools for the propagation of radar waves within concrete, aiming to predict the required antenna frequency and characteristics that are most effective in detecting internal concrete elements and defects of interest found in realistic structures. Form the modeling results obtained, which are described in this paper, a portable, advanced, single-channel GPR system was developed, which uses a highfrequency shielded dipole antenna in monostatic arrangement and operates at a central operating frequency of 2600 MHz. Finally, the evaluation of the performance of the developed GPR technology was carried out under laboratory conditions, where concrete samples of varying dimensions and with different embedded structural features of known characteristics were tested. The validation results produced from this study indicated the high potential and efficiency of the developed GPR device to accurately detect internal concrete features with superior resolution and with sufficient penetration for concrete to be adequately resolved in depths up to 40 cm.